Wall construction



Dec. 10, 1935. H, E VOEGEL; 2,023,452

WALL CONSTRUCTION Fay 5 \2/' gIENTOR l 7j 22 4 ATToRNEY Dec. 10, 1935. H. E. voEGELl v 2,023,452

WALL CONSTRUCTION Filed Feb. e, 1935 4 Sheets-Sheet 2 ATTO R N EYS Dec., 10, 1935. H. E. vox-:GELI

WALL CONSTRLCTION Filed Feb. e, 1955 4 Sheets-Sheet 3 INVENTOR TTORNEY 5:

Dec. 10, 1935. H. E. voEGELl WALL CONSTRUCTION Filed Feb. 6, 1953 4Sheets-Sheet 4 w ,il -w l.. 5% A@ .fw V l/wm l/7 M w V /9 9 /lb/ 8 9/ /9 @//L AoUw/ 9 M W. w.. w u f f f INwR ATTORNEYS.

Patented Dec. 10, 1935 )PATENT OFFIC WALL coNs'mUc'rIoN Henry E. Voegeli, Waterbury, Conn., assignor to The American Brass Company, Waterbury, Conn., a corporation of Connecticut Application February 6, 1933, Serial No. 655,347

9 Claims.

This invention relates to new` and useful improvements in wall construction and has for an object to provide an improved wall construction which will effectively exclude moisture and which may also include a heat insulating material. It is especially adapted for the use of sheet metal although not necessarily confined thereto.

Another object is to provide an improved joint for use in wall constructions and which joint while moisture proof will permit the sections or elements of the wall to expand and contract independently of one another under the influence of heat and cold.

A further object is to provide an improved construction of wall blocks, the blocks being so constructed as to overlap one another' and form weather tight joints and at the same time be free to expand and contract relatively.

Another object is to provide a wall block as stated and which may be formed of sheet metal.

and filled with insulating material.

An additional object is to provide a wall block including means whereby it may be easily and quickly secured in place on the frame of a, buildmg.

Other objects and advantages will become apparent from a consideration of the following detailed description taken in connection with the accompanying drawings wherein satisfactory embodiments of the invention are shown. However, it will be understood that the invention is not limited to the details disclosed but includes all such variations and modifications as fall within the spirit of the invention and the scope of the appended claims.

In the drawings:

Fig. 1 is a front elevational view showing several wall blocks constructed and assembled according to the present invention;

Fig. 2 is a view partly in section and partly in elevation, the view being taken substantially along the line 2-2 of Fig. l;V

Fig. 3 is an edge elevational view looking from the right in Fig. 1; f

Fig. 4 is a sectional view through a horizontal joint, the view being on an enlarged scale and taken substantially along the line 4-4 of Fig. 1;

Fig. 5 is a sectional view through a vertical joint, the view being on the same scale as that of Fig. 4 and taken substantially along the line 5-5 of Fig. 1;

Fig. 6 is a view somewhat similar to Fig. 4 but showing a slight modification;

Fig. 7 is a perspective view of the improved wall block;

(Cl. l2-18) Fig. 8 is a sectional view through a block illustratlng its construction;

Fig. 9 is a similar view illustrating a slightly modified construction;

Fig. 10 is an enlarged view of a portion of the block of Fig. 9; 5

Fig. 11 is a view similar to Fig. 4 but showing wall blocks of slate, stone, marble, cement or the like;

Fig. 12 is a view similar to Fig. 5 but showing blocks of the type shown in Fig. 11;

Fig. 13 is a horizontal sectional view illustrating a wall constructed according to the present invention;

Fig. 14 is a vertical sectional view through said wall;

Fig. 15` is a view somewhat similar to Fig. 14 but showing a slightly different application;

Fig. 16 is a view somewhat similar to Fig. 13 but showing a slightly different application; and

Fig. 17 is a plan view illustrating the pattern 20 for the metal shell or covering of the wall block of Figs. 1 through 7.

Referring in detail to the drawings, in Figs. 1 through 5 are shown portions of a Wall constructed of wall blocks 20 such as shown in 25 Fig. 7. Each block 20 includes a metal shell 2| filled as at 22 with any suitable or desirable material, as for example, heat insulating material, such as gypsum or porous concrete. If desired, a strengthening or reinforcing mesh 23 30 may be embedded in the insulating material 22 as shown in Fig. 2. The filling material may be applied in a plastic state and the mesh 23 will serve to prevent such material falling out of the shell 2| should the material become 35 cracked. Also, as will later be more fully pointed out, the mesh 23 assists in securing block mounting or attaching means to the blocks.

As most clearly shown in Figs. 2, 4, and 5 the metal of the shells 2| does not cover the entire 40 inner surface of the filling or insulating material but extends inwardly of the horizontal edge portions of the blofks as at 24 and of the vertical edge portions of the blocks as at 25. Figs. 1, 2, and 3 illustrate themounting of the blocks on 45 a building frame 26 and it will be noted that according to the drawings the blocks 20 are secured to the frame 26 by bolts 2l having their inner ends embedded in the material 22, the bolts extending rearwardly of the blocks and to having their ends passing through the frame members 26 and receiving suitable nuts 21a. A further block securing or mounting means comprises straps 28 welded or brazed to the metal shell 2|, and extending rearwardly of the blocks 55 and secured to the frame 26 as by pins or bolts 23. Either or both of the means 21 and 28 may be used, but it'is preferred to use the straps 28 when the material 22 is such as not to withstand strain and if bolts 21 are used when the nller or insulator 22 is of fragile material, the heads of the bolts be disposed beneath the mesh and enlarged or provided with washers to prevent the bolts pulling loose should material 22 crack or break.

From Figs. l through 5 it is apparent that the blocks 2|), when forming the outer surface of a wall, are arranged to overlap one another, and the horizontal joints I8 and vertical joints I9 between the blocks are such that the blocks may expand and contract independently of one another due to heat and cold and yet provide a weather tight wall. Fig. 4 illustrates the horizontal joint and it will be seen that the overlapping horizontal edges of the blocks are each cut or shaped to provide three steps 3|), 3| and 32 and that each step of the upper block is spaced from the corresponding step of the lower block. In addition to providing for expansion the space between the outermostJ steps 30 is of such width that water passing down the outer face of an upper block will not be carried into the joint by capillary action. Further, the two outermost steps 3|) and 3| of the upper edge of the lower block are inclined outwardly to provide water sheds. The upright or vertical walls 33 and 34 between the steps are in contact to keep out the weather.

As shown in Fig. 1 the vertical joints between the blocks are arranged in staggered 4relation and although this is not necessary it is preferred since a completed building will then have a more pleasing appearance. The vertical joint is shown on an enlarged scale in Fig. 5 and for this joint the blocks are provided each with two steps 35 and 36 and while one block is provided with an additional step 31 the other is provided with an outwardly projecting vertical rib 38. When the blocks are assembled their steps 35 and 36` are arranged in spaced relation to permit of horizontal expansion and contraction and to prevent the entrance of moisture into the joint by capillary action. The rib 38 divides the vertical space between the blocks into two enlarged chambers 39 and 40, the theory being that should wind carry water between the steps 35 of the blocks the wind will expand on reaching chamber 39 and lose its force and the water will go no farther, but will run down the walls of the chamber and be carried out as it reaches the lower joint. However, should it go farther it will be stopped by a similar action on reaching the somewhat smaller chamber 40.

A comparison of Figs. 4 and 5 will show that the inner step 36 of the vertical joint is of greater thickness than the inner step 32 of the horizontal joint. The relative proportions are such that the intermediate step 31 and the rib 38 of the vertical joint are forwardly of the vertical walls 34 of the horizontal joint and above the intermediate step thereof. The dotted lines 42, 43, and

44 of Fig. 4 show the location of the outer face of the rib 38 and the location of the walls 43 and 44 of the vertical joint with relation to the horizontal joint. From this it must be apparent that any moisture passing downwardly in the vertical joint will be delivered onto the intermediate step 3| of the horizontal joint, in advance of or outwardly of the wall 34 of that joint, and owing to the incline of said step will immediately pass outwardly to the face of the building.

In Fig. 6 is shown a slightly modified construction wherein the inner portion of the shell 20 at the upper edge of the block is carried up- 5 wardly and folded on itself as at 45 spanning and closing the space between the inner steps of the blocks.

When blocks of relatively large size are formed with straight outer metal walls they may bulge 10 outwardly when heated by the suns rays and detract seriously from the appearance of a building. To prevent this the structure of the blocks may be modied as shown in Fig. 8 wherein the block is generally designated 46 and includes a 15 metal shell having a forward face 41 the shell being lled with insulating material 48. The forward face 41 of the shell is slightly concaved or dished, as for example at the rate of onesixteenth of an inch per foot of breadth. With 20 this arrangement, on the face of the shell being heated, the shell will expand in a manner to push its edges outwardly as suggested by the arrow 49 and the metal face will not bulge outwardly. With small sized blocks this concaving 2;, would not be necessary.

Figs. 9 and 1D show another slightly modified arrangement and in these figures the block is generally designated 50 and includes an outer metal shell 5| and a filling 52 of any suitable insulating material. Anchoring bolts 53 are arranged in spaced relation and each has its forward end portion welded or brazed to the inner face of the shell 5I as at 54. To prevent the material 52 engaging the bolts adjacent the con- 5 nections between the bolts and the shell, cone shaped members are embedded in the insulating material and are about or enclosing the inner end portions of the bolts and the upper end may be hooked over the end of the cone as ino dicated at 53a. To anchor the cones in the material 52 ears 55a. may be struck from the walls and bent outwardly to lock he cone in the material so it will not be pulled outwardly by bolts 53. With this arrangement the inner or attached end 45 portions 54 of the bolts may shift laterally as the shell expands or contracts and these bolts being spaced apart and anchored to the cones and material 52 will prevent the metal wall 5| buckling or bulging outwardly under expansion from 54) heat. This support 53 is therefore exible and free to move with the wall 5| in any direction and will respond freely to the slightest tendency which the copper (or other metal) wall 5| may have to move laterally under temperature 55 changes, but always holds this wall snug against the fire proof material 52. The rod 53 may be flexible so if the upper end should become rigidly fixed the rod itself will bend to allow movement of the wall 5|. It could therefore be made e0 of wire of high fatigue resistance.

Figs. 11 and 12 illustrate joints 56 and 51 identical with the joints I8 and I9 and the functions of the joints in Figs. l1 and 12 are the same as those of joints I8 and I9. The sole difference be- 65 tween the blocks of Figs. ll and 12 and those of Figs. 4 and 5 resides in the fact that the blocks 58 of Figs. 11 and l2 do not include a metal shell. They may be molded and poured from cast metal, concrete or the like or they may be cut from slate, marble or the like. However, the blocks 58 illustrate that the improved joint herein disclosed is not limited to block structures including a metal shell and in Figs. 11 and 12 the same reference characters are applied to the various features of the joints as are applied to the corresponding features of the joints of Figs. 4 and 5.

Flg. 13 illustrates a construction wherein a block I9 constructed according to the present invention is bulged outwardly about a vertical column 60 forming a pilaster. Block 69 includes an outer metal shell 6| and a filling 62 of insulating material in which is embedded a reinforcing mesh 63. At one of its vertical edges it is equipped with the necessary steps and rib to provide the joint I9 previously described while its other edge is received by a window frame 6l and this edge of the block may be sealed or covered by a flashing 65. Beyond block 59'is shown a block 20 anchored as by a bolt 21 in the manner previously described.

'I'he inner wall construction as shown in Fig. 13 may include a layer 66 of gypsum, terra-cotta or rock wool on which is disposed a layer 68 of liquid asphalt. Next is disposed a vertical layer 69 of celotex or maftex board and then a horizontal layer 10 of celotex or maftex lath and a thin electro-sheet copper wall covering 1|.

Fig. 14 being a vertical sectional view illustrates the horizontal joint I8 between a pair of blocks 12 and 13 each including an outer` metal shell 14 and a lling 15 of insulating material in which is embedded reinforcing mesh 16. The block 12 has its lower edge 11 reduced and arranged in overlapping relationship with a window head 18 while the block 13 has its upper edge reduced and fitted under a window sill or ledge 19. The joint may be caulked as at 80.

Fig. 15 shows substantially the same structure as the lower portion of Fig. 14 with the exception that the lintel 8| is formed of hollow tile.

In Fig. 16, a horizontal sectional View, a block 12 has one of its vertical edges reduced as at 82 and abutting a window sash 83, the edge of the block being inwardly of a ashing 84 which, of course, may be caulked if desired.

Fig. 17 shows the pattern or a development of the metal shell 2| and it will be seen that the shell includes a face or body portion 85, from the edges of which extend flange-like portions 86, 81, 88, and 89. Flange-like portion 86 is folded along the lines 90 and 9| to form a step 35 at one edge of a block and along lines 92, 93, 94 and 95 to provide the rib 38 and along the other lines to provide the step 36 and the inner flange 25. By folding flange 81 along the lines 96 and 91 a step 30 is provided and then by folding along line 98 the first inner vertical wall is provided. Next, by folding along lines 99, |00, and |0| the step 3|, wall 4| and step 32 are provided, while folding along line |02 gives the inner horizontal flange 24. The small projection |03 provides a covering for one end of the rib. The ange 89 is similarly folded.

Folding flange 88 along the lines |04, |05, and |06 produces a step 35 and the wall between it and step 31 While folding on lines |01 and |08 gives the step 31 and the wall between it and `step 36. Folding on line |09 gives step 36 and folding on line I0 gives the other inner ange 25. After the metal blank is folded as outlined the corners abut and may be soldered o r Welded or the like.

From the foregoing description it will be apparent that I have provided a wall or building block which is impervious to moisture and which may be heat insulating and reproof. Brick walls have been found to be porous so as to absorb moisture and therefore have a tendency toward dampness and in addition bricks are fairly good conductors of heat. These objectionsare overcome by the block of the present invention and in addition the blocks are so constructed that the joints between them are weather tight and yet permit of expansion and contraction of the blocks under the influence of heat and cold. Also, the blocks may be easily and quickly assembled on a building frame and each block preferably has an outer surface of suitable metal as for example of copper. Therefore, the blocks will have long life and as particularly pointed out in connection with Figs. 8, 9, and 10 the blocks may be so constructed as to prevent bulging outwardly of their front walls when such walls are directed in and heated by the suns rays.

Having thus set forth the nature of my invention, what I claim is:

1. In a wall block, a metal shell including a front wall and edge walls, a body of insulating material lling said shell and having 'its front face and its edges cover-ed thereby, anchoring means secured to the inner surface of the front wall of the shell and extending rearwardly into the body to secure the shell and body together, and a hollow housing imbedded in said body about said means and engaging the inner surface of the front wall of the shell and serving to maintain the material of the body spaced from the inner portion of said anchoring means whereby to permit of lateral movement of said portion of ,the anchoring means with the shell independent of the body.

2. In a Wall block, a body having horizontal and vertical edges, three steps on one horizontal edge of said body, a pair of steps on one vertical edge of said body, an outwardly projecting vertical rib between said last steps and extending for the length of the inner thereof, and the innermost step of said vertical edge of greater thickness than the innermost step of said horizontal edge whereby said rib is disposed inwardly of the outer surface of the innermost horizontal step and moisture passing downwardly about said rib of one block will engage the intermediate step of the horizontal edge of the next lowermost block of a Wall and pass to the outer face thereof.

3. In a Wall block, a body having horizontal and vertical edges, steps on one horizontal edge of said body, steps on one vertical edge of said body, an outwardly projecting vertical rib ber tween said last steps, and the innermost step of said vertical edge of greater thickness than the innermost step of said horizontal edge whereby moisture passing downwardly about said rib of one block will engage an outer step of the horizontal edge of the next lowermost block of a wall and pass to the outer face thereof.

4. In a wall construction, an upper and a lower Wall block, said blocks having their adjacent horizontal edges overlapping and each divided into a plurality of steps, said blocks arranged with all of the horizontal edges of the steps of one in opposed spaced relation to the opposed horizontal edges of the. steps of the other to prevent the entrance of water between the blocks by capillary action, said blocks having their vertical walls between the steps in contact with each other, and a flange at the inner side of said lower block and extending upwardly beyond its innermost step to close the space between the opposed horizontal edges of the inner steps of the blocks at the inner side of the Wall.

5. In a wall construction, an upper and a lower Wall block, said blocks having their adjacent horizontal edges overlapping and each divided into a plurality of steps. said blocks arranged with all o! the horizontal edges of the steps of one in opposed spaced relation to the opposed horizontal edges of the steps ot the other to prevent the entrance of water between the blocks by capillary action, said blocks having their vertical walls between the steps in contact with each other, said lower block including a metal shell filled with insulating material, and said shell including an upstanding flange at the inner side of the block to close the space between the opposed horizontal edges of the inner steps of the blocks at the inner side oi the wall.

6. In a wall construction, a pair of wall blocks arranged in side by side relation with their vertical edges overlapped and each divided into a plurality oi steps, said blocks arranged with the vertical edges of the steps of one in spaced relation to the vertical edges of the steps of the other to permit of expansion and contraction of the blocks and with portions of their walls between the steps in contact, and an outwardly projecting vertical rib on one of said blocks between its steps, said rib projecting in the direction of the other block and providing a pair of separated enlarged spaces inwardly of the space between the vertical edges of the outermost steps of the blocks.

7. In a wall construction, a rst and a second block arranged in side by side relation with their vertical edges divided into steps and overlapped, the iirst of said blocks having its edge divided into three steps and the second having its overlapped edge divided into two steps, said blocks arranged with the vertical edges of the steps of one in spaced'relation to the vertical edges of the steps of the other, said second block having a portion of its wall between its steps in engagement with a portion of the wall between the steps of the nrst ot said blocks. a vertical rib on the said wall ot the second block, said rib projectin in the direction of the nrst block in spaced relation to the vertical edge oi the outermost step thereof, and said rib dividing the space provided between the blocks by the intermediate 2step of the ilrst block into a pair of chambers the rst and larger of which is immediately inwardly of the space between the vertical edges o! the outer steps oi the blocks.

8. InA a wall block, a body having horizontal and vertical edges, steps on one of the horizontal edges of said block, steps on one vertical edge of said block, and the inner step of the vertical edge oi the block being of greater thickness than the inner step of the horizontal edge thereof whereby moisture passing downwardly between the steps of the vertical edge of the blocl: is outwardly with respect to the inner step of the horizontal edge of the block so as to ow toward the outer wall and away from the inner wall of the block.

9. In a wall block, a body having horizontal and vertical edges, three steps on one vertical edge of the body, two steps on the other vertical edge of the body, the innermost steps at the two vertical edges of the body being of the same thickness, an outwardly projecting Vertical rib at that edge of the body having the two steps and projecting from the surface joining the two steps and being of less Width than this surface, and said rib of a thickness substantially equal to the thickness of the intermediate step at the other edge of the body.

HENRY E. VOEGELI. 

